Operator's Manual

MAESTRO 4SPCB Separator

2

Description TypePCB Separator MAESTRO 4S

Edition: 05/2014 Part No.: 9009613

CopyrightThis documentation as well as translation hereof are property of cab Produkttechnik GmbH & Co. KG. The replication, conversion, duplication or divulgement of the whole manual or parts of it for other intentions than its original intended purpose demand the previous written authorization by cab. EditorRegarding questions or comments please contact cab Produkttechnik GmbH & Co. KG.TopicalityDue to the constant further development of our products discrepancies between documentation and product can occur. Please check www.cab.de for the latest update. Terms and conditionsDeliveries and performances are effected under the General conditions of sale of cab.

Operator's Manual - Translation of the Original Version for the following products

Germanycab Produkttechnik GmbH & Co KGPostfach 1904 D-76007 Karlsruhe Wilhelm-Schickard-Str. 14 D-76131 KarlsruheTelefon +49 721 6626-0 Telefax +49 721 6626-249www.cab.de info@cab.de

Francecab technologies s.a.r.l. F-67350 Niedermodern Téléphone +33 388 722 501www.cab.de/fr info.fr@cab.de

USAcab Technology Inc. Tyngsboro MA, 01879 Phone +1 978 649 0293www.cab.de/us info.us@cab.de

South Africacab Technology (Pty.) Ltd. 2125 Randburg Phone +27 11-886-3580www.cab.de/za info.za@cab.de

Asia cab Technology Co., Ltd.

Junghe, Taipei, Taiwan Phone +886 2 8227 3966www.cab.de/tw info.asia@cab.de

China cab (Shanghai)Trading Co., Ltd.

Phone +86 21 6236-3161www.cab.de/cn info.cn@cab.de

Representatives in other countries on request

3Table of Contents

1 Introduction ............................................................................................................................................ 41.1 Instructions ............................................................................................................................................... 41.2 Intended Use ............................................................................................................................................ 41.3 Safety Instructions .................................................................................................................................... 41.4 Safety Marking ......................................................................................................................................... 51.5 Environment ............................................................................................................................................. 5

2 Technical Data ........................................................................................................................................ 6

3 Contents of Delivery .............................................................................................................................. 7

4 Control Panel .......................................................................................................................................... 7

5 Installation .............................................................................................................................................. 8

6 Switch on and Programming ................................................................................................................ 96.1 Switch on and synchronize the blade ....................................................................................................... 96.2 Programming ............................................................................................................................................ 96.3 Changing the Program ........................................................................................................................... 10

7 Adjustment the Cut Length ................................................................................................................. 10

8 Operation .............................................................................................................................................. 11

9 Maintenance ......................................................................................................................................... 129.1 Changing the Upper Blade ..................................................................................................................... 129.2 Adjustment of the Upper Blade Stopper ................................................................................................. 139.3 Check the Blade Alignment .................................................................................................................... 14

10 Errors .................................................................................................................................................... 14

11 EC Declaration of Conformity ............................................................................................................. 15

41.1 Instructions

Important information and instructions in this documentation are designated as follows:

Danger!Draws your attention to an exceptionally grave, impending danger to your health or life.

!Warning!Indicates a hazardous situation that could lead to injuries or material damage.

!Attention!Draws attention to possible dangers, material damage or loss of quality.

iNotice! Gives you tips. They make a working sequence easier or draw attention to important working processes.

Environment!Gives you tips on protecting the environment.

Handling instruction

Reference to section, position, illustration number or document.

Option (accessories, peripheral equipment, special fittings).

1.2 Intended Use• The device is manufactured in accordance with the current technological status and the recognized safety rules.

However, danger to the life and limb of the user or third parties and/or damage to the device and other tangible assets can arise during use.

• The device may only be used for its intended purpose and if it is in perfect working order, and it must be used with regard to safety and dangers as stated in the operating manual.

• The device is intended exclusively for separating pre-scored PCB's. Any other use or use going beyond this shall be regarded as improper use. The manufacturer/supplier shall not be liable for damage resulting from unauthorized use; the user shall bear the risk alone.

• Usage for the intended purpose also includes complying with the operating manual, including the manufacturer‘s maintenance recommendations and specifications.

iNotice! The complete documentation can also currently be found in the Internet.

1.3 Safety Instructions• The device is configured for voltages of 115 or 230 V AC. It only has to be plugged into a grounded socket.• Hazard by electrical charge. Provide an earthing connection via press stud. • Only connect the device to other devices which have a protective low voltage.• Switch off all affected devices (e.g. conveyor belt) before connecting or disconnecting.• Risk of hand injury. Wear protective gloves while PCB separating.• Ensure that people‘s clothing, hair, jewelry etc. do not come into contact with the exposed rotating blade.• In an emergency situation, actuate the emergency stop switch in the control panel by tight pressing. This inter-

rupts the voltage supply to the device. • The device may only be used in a dry environment, do not expose it to moisture (sprays of water, mists, etc.).• Do not use the device in an explosive atmosphere.• Do not use the device close to high-voltage power lines.

1 Introduction

5• Work going beyond this may only be performed by trained personnel or service technicians.• Unauthorized interference with electronic modules or their software can cause malfunctions.• Other unauthorized work on or modifications to the device can also endanger operational safety.• Always have service work done in a qualified workshop, where the personnel have the technical knowledge and

tools required to do the necessary work.• There are various warning stickers on the device. They draw your attention to dangers.

Warning stickers must therefore not be removed, as then you and other people cannot be aware of dangers and may be injured.

Danger!Danger to life and limb from power supply.

Do not open the device casing.

1.4 Safety Marking

4

3

2

1

Fig. 1 Safety marking

1 Emergency Switch Press it in a hazardous situation!

2 Risk of hand injury ! Wear protective gloves while PCB separating.

3 Possible damage of electronics ! Disconnect the PCB separator from the electrical outlet before mounting or

removing an optional conveyor belt.4 Hazard by electrical charge !

Provide an earthing connection via press stud.

Table 1 Safety marking

1.5 Environment

Obsolete devices contain valuable recyclable materials that should be sent for recycling. Send to suitable collection points, separately from residual waste.

The modular construction of the printer enables it to be easily disassembled into its component parts. Send the parts for recycling.

1 Introduction

6 2 Technical DataTechnical data 4S/450 4S/600

Separation type Component side: Soldering side:

circular bladelinear blade

Operation motorized and optimizedSeparation speedt 300/500 mm/sec. switchableMaterial FR4, AluminiumHeight of components Component side/Soldering side up to 34 mmCutting length , continuous F up to 450 mm up to 600 mmLength D 702 mm 852 mmDepth storage table 200 mmProgrammingHome Request drive to starting position, AcknowledgeSpeed H (High): 500 mm/Sek.

L (Low): 300 mm/Sek.Program 9Step (cutting steps) 1 – 5Distance (between blades) 0,9 mm bis 0,05 mmKey switch button Release of programmingMileage (Kilometer counter) up to 99,99 kmDEL Reset of the kilometer counterPower switch ON/OFFFoot switch START SeparationSafety switch Emergency stopSpannung 100–240 V~ 50/60 HzEmission sound pressure level LpA < 70 dB (A)Temperature / humidity not condensing

Operation +10–35°C / 10–85%Stock +20–50°C / 20–80%Transport -25–50°C / 20–80%

Weight 38 kg 46 kgHeight/Depth 434x425 mmWidth 702 mm 852 mmApprovals CE, FCC class A

Dimension Maximum Height of components on the cut nut

27 21,5

3434

400.

..40

10̊10̊

Enlargement of the PCB outside after separation. typical 0,2 mm

30̊

0,8

- 3,2 m

ax. 0

,8

min

. 0,2

5

FR4

30̊

0,8

-1,5 m

ax. 0

,3

min

. 0,2

5

Alu

The cut nut could be broken by a cutout.In case of overlaying components, the linear blad must be hollowed.If required request.

Table 2 Technical data

73 Contents of Delivery

56

4

2

1

3

1 Maestro 4S/300 (600)2 Power Cable3 Dial Gauge Assembly4 Food Switch5 Hexagonal Wrench DIN911 2mm6 Hexagonal Wrench DIN911 5mm7 Documentation

Fig. 2 Contents of Delivery

Gelb Pantone 123C, Grün RAL 6018, Blau Pantone 7461, Grau Pantone 422C, Beschriftung, Fenster- und LED-Umrandung Schwarz, Fenster- und LED-Fond Filtergrau. 29.10.2013 Lortz1 3 5 7 9 10 12 14

1513118642

Fig. 3 Control Panel

1 Button home - Synchronization after switch-on - Quit of errors in operation

2 LED not ready Is blinking in case of error or missing synchronization of thr blade. 3 Button speed Choice of speed.4 Display speed Display the selected speed; L (Low) and H (High)5 Button program Program choice.6 Display program Display the selected program.7 Button step Choice the cut of the material separation in the program. 8 Display step - Show the current cut in the operation.

- Show the selected cut in the program .9 Button distance - Make the distance between blades smaller

10 Button distance + Make the distance between blades bigger.11 Display distance Display the distance between blades.12 Button key Switch on the programming mode.13 LED key Is blinking in programming mode.14 Button DEL Reset display mileage15 Display mileage Total length of all cuts from zero position

Table 3 Control Panel Elemets

4 Control Panel

8 5 Installation

!Attention!The device and printing materials will be damaged by moisture and wetness.

Set up the device only in dry locations protected from splash water.

4

5

7

321

6

Fig. 4 Connections

Set up device on a level surface. For a secure stand you can change the foot highness by turning. Put in the foot switch round connector (4) from the foot switch (7) in the 5 pin female connector (2) and tighten it. Connect the electrical ground on the earth connection (6) . Switch off the power module (1).Connect the power cable (5) to the power input module (3) and to an earthed

socket.

9

iNotice! You can separate PCB panel with multiple cuts very softly. It means, more cuts are gentle for material and elements on the PCB board.

6.1 Switch on and synchronize the blade

1. Switch on the device by power switch (1) . LED not ready is blinking.

iNotice! Are all connections ready and the device is swiched on and not in function check the emergency swith!

1

Fig. 5 Power Switch

2. Press button home.3. Press the foot-switch and hold it.

- Device will run to the start position or from the start position short out and back into the start position.4. Loose the foot switch and the device is ready. LED not ready don't glow.

It's possible to use 9 program places. After the first switch on the program 1 will be loaded.

Setting ex factory:Material separation in 3 cuts,with increasing cut deepness respectively declining blade distance . 1. cut = blade distance: 0,6 mm 2. cut = blade distance: 0,3 mm 3. cut = blade distance: 0 mm

6.2 Programming

1. Press button program and hold it over 3 seconds. The display of the selected program is blinking.

2. Select desired program place by the button program. 3. Press the button key progr. for 3 seconds up to the LED key is blink.4. Select cut step by the button step.5. With the button distance - and distance + adjust the distance of the blades for this cut step.

- maximum distance = 0,6 mm Adjusting in steps of = 0,05 mm - minimum Distance = 0 mm

6. Select next cut step.7. Adjust the blade distance

- Blade distance smaller the former distance and higher 0 mm; back to point 5. - Blade distance = 0 mm or the same value as the former distance and pressing the button step; closing the programming mode. LED key don't glow. In case of end programming with two same distance value with a value greater 0 mm is the last cut a cut in this distance. Maximum 5 cuts are possible.

6 Switch on and Programming

10

iNotice! The adjusted cut length must be orientated on the separated PCB. Then, the display "mileage" for the cut length shown a realistic value.

Schnittlänge

a b

33

22

Fig. 6 Length of cut

1. Loosen easy knurled screw (1 and 2) and move it to the maximum outside position.

iNotice! Don't loosen the knurled screws (1 and 2) complete. loosen it only easy.

2. Activate the foot switch to start and run the program one times. The carriage will be now in a Endposition and the lower blade is free.

3. Hold the PCB on an any position between the both knurled screw. 4. Move the knurled screws (1 and 2) to the outside edges of the PCB and tighten the screws.

iNotice! The distance between the knurled screws (1 and 2) must be 20mm minimum. In case of a smaller distance, the sensors will not detected and the blade will run over the full length.

5. Activate the foot switch to start and run the program one times.6. The carriage is standing now in the first cut position.7. Put the PCB into the adjusted cut area (a to b) on the lower blade and move it in direction to the round blade

midpoint ca. 10 mm under the carriage (3) .8. Check the setting with a test cut and maybe make a fine adjustment.

6 Switch on and Programming

7 Adjustment the Cut Length

6.3 Changing the Program

Switch between program 1 - 9 Press button program and hold it over 3 seconds.

The display of the selected program is blinking. Select the program by pressing the program button. If the button program not used for 3 seconds, the program display will end the blinking and the new program is

selected.

118 OperationIf the device switched of an d on it' will start in the last program before switched off.

1. Switch on the device by the power-switch (1). LED not ready blinking.

1

Fig. 7 Power Switch

2. Press button home.3. Press the foot-switch and hold it.

- Device will run to the start position or from the start position short out and back into the start position.. - Synchronization of the blades.

4. Deblock the foot-switch - device is ready for operation. LED not ready don't glow. 5. Select program. If you switch of and on the last used program is selected. After first switch on program 1 is

selected. 6. Put in the PCB panel.7. Press the foot-switch to start the program. Foot-switch must be pressed over the length of the program.8. Deblock the foot-switch after program end.

iNotice! In case of uneven number of cuts will be an other start position for the next program start.

Reset the display of cut length Press button DEL for 3 seconds.

Display mileage blinking. In the next 3 seconds press button DEL again to reset the display to Zero.

129.1 Changing the Upper Blade

In case of wasting, damage or material cahange it's necessary to change the upper blade.For cutting FR4 PCB material will used the blade with cab part number 8930509.001 . For cutting Aluminium will used the blade with cab part number 8936895.001 .

Danger!Risk of cutting damage by rotating blade! Disconnect device before you start service work!

1 2 3 4

87

1211109

5

8b8a6 6

Fig. 8 Changing the upper blade

1. After switching off the device and disconnecting from power supply, pull connector (2) out from female connector (3) on the motor.

2. Slide the carriage to the left end position (front view). Like upper picture.

3. Set the setting knob (5) on value 16 - blade on the highest position.

4. Swing lever (6) in position a to decouple.5. Loosen screws (4) and remove table (1) by

movements back and top.6. Loosen screws (8).7. Remove motor carriage with mounted motor (7).8. Hold the setting knob (5) and loosen the knurled

nut(12) .9. Remove blade (11) . It's possible that the washer

(10) are adhere on the blade. Remove the Washer (10) from bladeand take it back on the axle (9).

10. Take the new blade (11) on the axle (9).11. Hold the setting knob (5) and tighten the knurled

nut(12) .12. Set the setting knob (5) on value 16. 13. Mount motor carriage with mounted motor (7) and

tighten screws (8) .14. Swing lever (6) in position b to couple.15. Hang up the table (1) and tighten screws (4) .16. Put in connector (2) into female connector (3) on the

motor.

iNotice! Adjust the stopper of the upper blade before you start operation. chapter 8.2

9 Maintenance

139.2 Adjustment of the Upper Blade Stopper

iNotice! The lower stop of the upper blade adjustment is already adjusted by delivery.

After a long operation time, while working at strongly varying temperatures or else after replacing a blade, it is recommended to re-adjust the lower stop.

3 5 6

1 2

4

74

8b8a

Fig. 9 Adjustment of the upper blade stopper

1. Move the lever (8) to the position 'a'. The motor drive to the blade carrier (1) is now disconnected.2. Move the upper blade carrier (1) in the middle position of the lower blade.3. Rotate the pointer (2) with the knob (4) counterclockwise to position "16".4. Loosen the screw (3).5. Move the knob (4) clockwise until the upper and lower blades are in a distance of 0.03 mm. Use a thickness

gauge.6. Swing the strut (5) clockwise until you reach the stop and tighten the screw (3). This adjustment locks the upper

blade in place to prevent it from moving out of adjustment. 7. Move the lever (8) to the position 'b'. The motor drive to the blade carrier (1) is now reconnected.

9 Maintenance

149.3 Check the Blade Alignment

iNotice! When the machine is put into operation for the first time, or following a move of equipment or a change of blades, it is advantageous to re-check the alignment of the blades in relationship to one another. For this purpose a dial gauge assembly (Part No. 8970208) is available as an option.

1

2

3

45

6

7

6

7

4

10

9

0,0 - 0,2± 0,1

Roller Blade 8930509.001 FR4

Roller Blade 8936895.001 Al

Fig. 10 Check the blade alignment

1. Move the blade carrier (1) to the middle of its range of travel.2. Affix the dial gauge assembly onto the threaded hole (2) in the blade carrier and screw tight with the knurled

screw (4) provided. Ensure that the small spigot (5) mounted on the inside of the lever (6) locates correctly into the hole (3) provided in the blade carrier.

3. Swing the lever (6) upwards until the tip of the gauge feeler (7) presses onto the upper blade (9) at 2 mm of the edge of the blade. Rotate the scale on the dial gauge until the pointer in the 1/100 mm division is lined up with the „0“ on the scale.

4. Swing the lever (6) downwards until the tip of the gauge feeler (7) presses onto the lower blade (10) at 2 mm of the edge of the blade. Depend of blade type (fig. 9 - right) the results achieved from measuring along the complete length of the lower blade may not vary by more than ±0.1 mm respective 0-0.2 mm from the values obtained from the upper blade measurements.

5. In the event of the values obtained by the above procedure being greater than the values like figure 9 , the servicing agent responsible for your machine should be contacted.

6. Remove the dial gauge assembly.

10 Errors

Cause of error Effect / Display Error recoveryThe food-switch is clear in the moment of synchronization

LED not ready Display step Display distance Display cut length

blink

Switch of the device and switch it on again. New synchronization

The device is switched on and the carriage with the upper blade will moved by hand out of the start position The carriage with the upper blade is blocked in operation.

LED not ready blink Press button home Press the foot-switch and hold it a Device will run into the start position

Clear the foot-switch A new activation of the food-switch will continue

the program with a replay of the last cut.

The food-switch will be clear if the program is running.

Material is not separated after program end

Switch of the device and make a new synchronization .

Chang programing - More cuts - Reduce the distance between upper and lower blade in smaller steps

Table 4 Errors in operation and handling

9 Maintenance

15

Gesellschaft für Computer- und Automations- Bausteine mbH & Co KG Wilhelm-Schickard-Str. 14 D-76131 Karlsruhe, Germany

EC Declaration of Conformity

We declare herewith that the following device as a result of design, construction and the version put in circulation complies with the relevant fundamental regulations of the EC Rules for Safety and Health. In the event of any alteration which has not been approved by us being made to any device as designated below, this statement shall thereby be made invalid.

Description: PCB SeparatorDevice: MAESTRO 4S

Applied EC-Directives and Standards :Directive 2006/42/EC on machinery • EN ISO 12100:2010

• EN ISO 13857:2008• EN 349:1993+A1:2008• EN 60204 -1:2006+A1:2009• EN 61029-1:2009+A11:2010• EN 61558-1:2005+A1:2009

Directive 2004/108/EC relating to electromagnetic compatibility • EN 61000-3-2:2006+A1:2009+A2:2009• EN 61000-3-3:2008• EN 61000-6-2:2005• EN 61000-6-4:2007+A1:2011

Person authorised to compile the technical file : Erwin Fascher Am Unterwege 18/20 99610 Sömmerda

Signature for the producer :

cab Produkttechnik Sömmerda Gesellschaft für Computer- und Automationsbausteine mbH 99610 Sömmerda

Sömmerda, 24.02.14

Erwin Fascher Managing Director

11 EC Declaration of Conformity

16